Client & task
Zhongwei is a manufacturer of NTC sensors. Although market demand is strong, intensifying competition pushed the company to increase output and reduce unit costs in order to win greater market share and improve margins. In the legacy process, operators manually soldered lead wires to NTC resistor leads. This limited throughput and introduced variability that could affect sensor accuracy. Zhongwei asked us to replace this manual step with an automated station that would raise line productivity and ensure consistent solder joint quality.
Our approach
After detailed process mapping with Zhongwei’s engineers, we implemented a two station solution.
Upstream station: automatic wire feeding, cut to length, insulation stripping, wire twisting, flux dipping, tin dipping, and tray loading in one continuous unit.
Downstream station: a dedicated automatic soldering machine that takes the tray loaded wires and solders them to the NTC resistor leads.
The two stations are coordinated by tray handoff to keep the workflow organized and consistent.
Based on projected throughput increase and direct labor savings, the investment is expected to reach payback in about one year. The estimate reflects fewer operators per shift, shorter cycle time.
Fully Automated Production
From wire cutting to soldering, the process runs unattended.
Consistency and Stability
Driven by servo motors and controlled by PLC with a touch screen.
Expansion and Upgrades
Modular design. Upstream and downstream equipment can interface seamlessly to support future line upgrades.
MES and WMS Compatible
Connects to MES and WMS for efficient production management.
insulation stripping
wire twisting
flux dipping
tin dipping
tray loading
soldering
The Results
Before delivery we completed a one month trial production. The equipment delivered a significant increase in throughput, reduced manufacturing cost, and high yield with consistent product quality.
The machine delivers consistently high quality resistor soldering, with neat joints and excellent consistency. It has exceeded our expectations.
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- Sales Manager
- Hunter
Huizong delivers scalable automated production equipment that syncs with upstream and downstream lines to boost efficiency and quality.
With 20+ years of experience, we integrate AGVs, robots, MES and WMS into reliable smart factory solutions for diverse industries.
